US7690554B2 - Anti-sifting polygonal carton and methods of assembly - Google Patents
Anti-sifting polygonal carton and methods of assembly Download PDFInfo
- Publication number
- US7690554B2 US7690554B2 US11/548,959 US54895906A US7690554B2 US 7690554 B2 US7690554 B2 US 7690554B2 US 54895906 A US54895906 A US 54895906A US 7690554 B2 US7690554 B2 US 7690554B2
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- Prior art keywords
- carton
- flap
- major
- miter
- flaps
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D5/00—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
- B65D5/02—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding or erecting a single blank to form a tubular body with or without subsequent folding operations, or the addition of separate elements, to close the ends of the body
- B65D5/0227—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding or erecting a single blank to form a tubular body with or without subsequent folding operations, or the addition of separate elements, to close the ends of the body with end closures formed by inward folding of flaps and securing them by heat-sealing, by applying adhesive to the flaps or by staples
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D5/00—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
- B65D5/02—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding or erecting a single blank to form a tubular body with or without subsequent folding operations, or the addition of separate elements, to close the ends of the body
- B65D5/0263—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding or erecting a single blank to form a tubular body with or without subsequent folding operations, or the addition of separate elements, to close the ends of the body with end closures formed by inward folding of flaps, three of them being formed of a continuous strip, the fourth being a separate flap
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D5/00—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
- B65D5/02—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding or erecting a single blank to form a tubular body with or without subsequent folding operations, or the addition of separate elements, to close the ends of the body
- B65D5/029—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding or erecting a single blank to form a tubular body with or without subsequent folding operations, or the addition of separate elements, to close the ends of the body the tubular body presenting a special shape
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D5/00—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
- B65D5/42—Details of containers or of foldable or erectable container blanks
- B65D5/4279—Joints, seams, leakproof joints or corners, special connections between panels
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D5/00—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
- B65D5/42—Details of containers or of foldable or erectable container blanks
- B65D5/44—Integral, inserted or attached portions forming internal or external fittings
- B65D5/441—Reinforcements
- B65D5/443—Integral reinforcements, e.g. folds, flaps
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D5/00—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
- B65D5/42—Details of containers or of foldable or erectable container blanks
- B65D5/54—Lines of weakness to facilitate opening of container or dividing it into separate parts by cutting or tearing
- B65D5/5405—Lines of weakness to facilitate opening of container or dividing it into separate parts by cutting or tearing for opening containers formed by erecting a blank in tubular form
- B65D5/541—Lines of weakness to facilitate opening of container or dividing it into separate parts by cutting or tearing for opening containers formed by erecting a blank in tubular form the lines of weakness being provided in one or more closure flaps
Definitions
- This application relates generally to polygonal cartons used in packaging bulk product packages and more particularly, to polygonal cartons used in packaging granular detergent or other material packaging.
- At least some known polygonal cartons use a combination of major, minor, and/or miter panels to facilitate sealing the corners of the polygonal carton in the bottom and the top.
- Such cartons when folded and glued upon the bottom, receive a product in a main compartment defined therein, and the top is then folded and glued to seal the carton for shipping.
- Carton designs used in packaging bulk granular products are fabricated with both partial and full seal end constructions.
- the product is activated, as is the case with detergents, or deteriorates as may occur with foods and pet products.
- dry bulk products require a moisture resistant and sealed carton that prevents direct contact of the bulk product with moisture, such as water, and indirect contact such as through humidity.
- dry bulk products must meet customer expectations and reduce the losses encountered by bulk product distributors. In addition, to further meet customer expectations and to reduce losses that may be encountered by distributors, cartons must minimize sifting of product out of the carton.
- known cartons start as a continuous plane or blank of material, such as paperboard. After folding, stress points may be created in the blank at each fold, and more particularly, at each corner.
- rectangular-shaped cartons generally are susceptible to sifting because the corners of such containers endure stress from folding along two axes. Moreover, during shipping and handling, the corners of such cartons may wear down and over time, may enable the product to be inadvertently released through a process commonly called sifting.
- the present invention provides an octagonal shaped carton that contains bulk granulated product while minimizing sifting from the carton.
- cartons are folded and erected into a generally rectangular finished shape.
- the present invention utilizes a carton formed by specialized machinery that erects a carton and securely seals the end flaps.
- Containers, or cartons, for bulk, or granulated, products are known in the prior art. Older cartons held the granulated products within octagonal shapes, such as with gussets. However, a combination of major, minor, and miter flaps, folded and glued by specialized machinery make few appearances in the prior art.
- U.S. Pat. No. 1,892,715 to Wellman is directed to a receptacle in its blank from.
- the receptacle contains a plurality of side walls that overlap, when glued, into the configuration of an octagonal shaped carton.
- the carton contains an integral bottom wall and likewise has a top closure, when folded into its usable configuration.
- U.S. Pat. No. 2,787,408 illustrates a quick set-up folding container, bag-like and hexagonal in shape.
- U.S. Pat. No. 3,990,210 shows a very similar mandrel formed carton which is a divisional patent of the McDonough '088 patent described above.
- the patent to Ljungcranzt U.S. Pat. No. 4,094,124, shows a process and apparatus for the manufacture of filled closed containers.
- the apparatus incorporates a mandrel for shaping a blank, into a carton, during its erection, and filling.
- U.S. Pat. No. 4,470,540 is directed to an open top, set-up container with a uniquely shaped, albeit octagonal, form and a uniquely folded bottom.
- U.S. Pat. No. 1,425,549 discloses a symmetrical octagonal carton, formed as a paperboard box for containing hats and other millinery products.
- a plurality of side panels form the octagonal shape and the bottom panels fold over to provide closure.
- Upper panels incorporate a pair of major flaps, miter end flaps, and miter flaps that are arranged intermediate thereof, and which are folded over to accommodate an overlying relationship with the major and miter flaps, and adhered thereto for closure.
- U.S. Pat. No. 2,565,188 is directed to shows another polygonal box, an octagon.
- the box includes a variety of flaps, functioning as major flaps, with a series of miter flaps, which interlock with the major flaps during closure.
- U.S. Pat. No. 4,119,266 describes an octagonal shaped paperboard bin that includes slotted flaps for retention of the top of the carton.
- U.S. Pat. No. 4,225,078 describes a knocked-down polygonal container with set-up contour-forming flaps.
- the container is open at its top, and its bottom includes a series of flaps that fold inwardly to form a bottom closure.
- U.S. Pat. No. 4,260,100 is directed to a container closure including a series of end flaps that are pivotally connected to the sides of the outer closure panels to close the top of the carton. The flaps tuck into the carton, rather than providing any type of a miter support for the erected carton.
- U.S. Pat. No. 4,361,267 describes a four-corner design for an octagonal container wherein corner flaps provide an engagement flap, for tuck-in purposes, to secure the container into closure.
- U.S. Pat. No. 4,392,607 is directed to a carton including integral closures that form an octagonal shape and that overlap a plurality of top miter flaps to engage with flap strips.
- U.S. Pat. No. 4,702,408 describes a bulk bin formed into an octagonal shape designed for the shipment of heavy quantities of fresh meat. A top closure is not described and its bottom closure incorporates a variety of flaps that tuck into each other.
- U.S. Pat. No. 5,630,543 describes a one-piece octagonal box including closure and folding flaps that have more of the bellows style of closure.
- U.S. Pat. No. 6,446,859 describes a foldable storage container that is an octagonal box. Its upper closure forms a recessed closure. And it includes lid panels that are sized to fit within polygonal folded sheets.
- U.S. Pat. No. 6,471,102 is directed to an easy-opening handled carton, that includes a tear strip, which when opened, enables a central portion of the major panel to be pulled free.
- top and bottom units are attached to the inner surface of the walls.
- U.S. Pat. No. 6,588,651 describes an octagonal bulk bin. At least one side wall includes at least one score line that is weakened to buckle the wall in a controlled manner.
- U.S. Pat. No. 5,704,540 describes a carton fabricated with rigid sheet material and a handle. The carton folds into an octagonal shape.
- U.S. Pat. No. 5,878,946 describes a carton or cover of rigid sheet material with a reinforced handle, and a blank and process for manufacturing the same.
- the carton when formed, generally has an octagonal shape.
- U.S. Pat. No. 5,943,840 to Nilsson, et al., is directed to a method and apparatus for forming a top of a container.
- the carton when assembled upon the multi-mandrel machine, is generally rectangular.
- U.S. Pat. No. 6,042,527 is directed to a carton forming device which is used to form a rectangular carton.
- U.S. Pat. No. 6,202,920 describes a gusseted carton, which uses its end formation, including all of its gussets, forms the shape of its top panels, which are octagonal.
- polygonal carton according to the present invention substantially departs from the conventional concepts and designs of the prior art, and in doing so provides a device primarily developed for the purpose of sealing and reinforcing carton corners to reduce sifting of granulated products from cartons.
- the present invention provides a single piece bulk granular product carton.
- the carton comprises a blank having major flaps, lower major flaps, minor flaps, miter flaps, emboss pads, a front panel, a rear panel, miter panels, notches, and a tear strip.
- the panels form a polygonal such as an octagon-shaped carton with the flaps used for closing the ends of the carton.
- the flaps overlap to seal the four corners of each end. With sealed ends, sifting and/or other losses of granulated product from the carton are facilitated to be reduced.
- the polygonal carton addresses the sifting problem with a combination of minor flaps, miter flaps, emboss pads, and offset scores in various locations.
- the first-down major flap is folded by intricate machinery to support the structure.
- the minor and miter flaps are flared by the intricate machinery and glue is extruded onto the structure to “caulk” all potential points of leakage holes.
- a deboss area at each end of the major flap enables more glue to fill-in gaps that may be formed between the major, miter, and minor panels, such that an amount of stress induced to each corner is reduced, and such that the likelihood of creating sift openings is also facilitated to be reduced.
- the intricate machinery is used to fold and retain the major and miter flaps into place. Finally, intricate machinery is used to force the last-down major flap into place to create an eight-sided sift-resistant structure that can be produced with high production speeds.
- the present invention forms upon specialized machinery that allows gluing of all flaps. Gluing occurs as machinery first forms the blank into a tube as the precursor to a carton. The bottom of the carton is then formed as the minor and miter flaps are flared out and the first major flap is folded. Glue is then applied to the first major flap, thereupon the minor and miter flaps are folded to meet the first major flap, thus being securely glued and sealed.
- the second major lower flap is folded and glued to the minor, miter and first major flap such that the minor and miter flaps are layered between the first and second major flaps. This seals the bottom of the carton.
- the same process used for folding and sealing the bottom of the carton is used for the top of the carton. The carton is now ready for shipping and sale to consumers.
- the carton has a closer and more airtight seal. Further, pinhole gaps have less effect as each miter, front and rear, and side panel is folded at forty-five degrees to form the octagonal carton. Moreover, all minor panels meet when formed, thus mitigating stress and/or fiber tears at the corners.
- An emboss pad on the second major lower flap fills the gap created by the partial overlap of the first major lower flap when sealing the bottom of the carton.
- the anti-sifting polygonal carton is a paperboard container of a single blank of material that forms an eight-sided carton.
- the carton includes trapezoidal minor flaps upon four miter panels, two side panels with attached minor flaps, and front and back panels with attached major flaps.
- the major flaps enable opening and re-closing of the top, when initiated by a tear strip opener.
- One object of the present invention is to provide a new and improved polygonal carton that contains granulated product without sifting.
- Another object is to provide such a carton that is octagonal in shape that differentiates the carton from other manufactures in the eyes of the consumer.
- Another object is to provide such a carton that is formed upon specialized machinery for accuracy of folding and integrity of sealing.
- Another object is to provide such a carton that has a higher vertical load capacity, or top load compression strength, than rectangular cartons allowing for higher stacking of cartons at warehouses.
- FIG. 1 illustrates a plan view of a reverse face of a blank of an exemplary embodiment of an anti-sifting polygonal carton assembled in accordance with the principles of the present invention
- FIG. 1A illustrates adhesive applied to the blank shown in FIG. 1 ;
- FIG. 2 is an isometric view of the polygonal carton shown in FIG. 1 ;
- FIG. 3 is a front view of the carton shown in FIG. 1 ;
- FIG. 4 is a rear view of the carton shown in FIG. 1 ;
- FIG. 5 is a side view of the carton shown in FIG. 1 ;
- FIG. 6 is a top view of the carton shown in FIG. 1 ;
- FIG. 7 is a bottom view of the carton shown in FIG. 1 .
- FIG. 1 illustrates a plan view of a reverse side of a blank 2 of an exemplary embodiment of an anti-sifting polygonal carton 1 .
- FIG. 1A illustrates the glue 4 applied to blank 2
- FIG. 2 is an isomeric view of carton 1 .
- FIGS. 3-5 are respective front, rear, and side views of carton 1 and FIGS. 6 and 7 are respective top and bottom view of carton 1 .
- anti-sifting polygonal carton 1 starts as a flat blank 2 that is somewhat H-shaped, and is generally symmetric, with four contiguous sections ( 2 a , 2 b , 2 c and 2 d ).
- the contiguous sections include a side section 2 a , a front section 2 b , a side section 2 c , and a rear section 2 d .
- Each side section 2 a and 2 c includes two miter panels 6 and rear section 2 d includes notches 7 a and a separate miter tab 7 .
- the first section 2 a extends outward from the center of the blank 2 along the longitudinal axis of the blank 2 .
- a side panel 5 is generally rectangular in shape and is positioned such that a longitudinal axis of the side panel 5 is substantially perpendicular to the longitudinal axis of the blank 2 .
- the length of the side panel 5 establishes the general height of the finished carton 1 .
- the side panel 5 has longitudinal creases 5 a and lateral folds 12 a of shorter length than the longitudinal creases 5 a .
- minor flaps 10 Extending away from the lateral folds 12 a upon both ends, minor flaps 10 have a generally trapezoidal shape with a short base and a substantially parallel long base that is spaced a distance from the short base with edges joining the two bases.
- the short base is substantially contiguous with the side panel 5 at a lateral end along a fold line 12 a .
- a minor flap 10 contacts a major flap or a major lower flap.
- miter panels 6 extend along the longitudinal creases 5 a of the side panel 5 .
- the longitudinal axes of miter panels 6 are substantially parallel to the longitudinal axis of the side panel 5 .
- the miter panels 6 are generally rectangular shaped and each has a length that is less than, or equal to, approximately half the width of a side panel 5 .
- the miter panels 6 also have lateral folds 12 b and longitudinal creases 6 a .
- the lateral folds 12 b connect miter flaps 6 b with miter panels 6 .
- Miter flaps 6 b are generally triangular shaped with the base of the triangle defined along the fold 12 b and the vertex of the triangle positioned away from miter panel 6 .
- each end of each miter panel 6 includes a miter flap 6 b .
- second section 2 b Extending away from first section 2 a , towards the center of blank 2 , second section 2 b includes a front panel 3 , as appended second major flap 9 b , and a second major lower flap 8 b .
- Front panel 3 has a generally rectangular shape with a longitudinal axis that is substantially parallel to the longitudinal axis of blank 2 .
- Front panel 3 also has lateral ends that are contiguous with miter panel creases 6 a , and longitudinal sides that are contiguous with folds 12 c to second major flap 9 b and to second major lower flap 8 b.
- the second major flap 9 b has a generally trapezoidal shape defined by a short base and a substantially parallel long base that is spaced from the short base and is joined thereto joined by a pair of edges.
- the short base is contiguous with a fold 12 c upon the longitudinal side of the front panel 3
- the long base is positioned away from the center of the blank 2 , or towards the center of the assembled carton 1 .
- the pair of edges are substantially straight and have an end proximate to the short base that is truncated at an approximate forty-five degree angle.
- the miter flaps 6 b abut the second major flap 9 b at the truncated edges.
- the second major flap 9 b also has a tear strip 13 that extends across flap 9 b adjacent to the long base.
- Tear strip 13 is substantially parallel to, and spaced apart from, the long base, and the tear strip 13 enables a consumer to open the assembled carton 1 .
- the tear strip 13 includes a thin line of tape 13 a upon the reverse side to provide ripping strength.
- the tear strip 13 creates a plurality of partial cuts 13 b and 13 c within the second major flap 9 b .
- the first partial cut 13 b is defined away from the center of the blank 2 and extends for substantially the full length of second major flap 9 b .
- the second partial cut 13 c is spaced apart from and is parallel to, first partial cut 13 b , extends across two portions of second major flap 9 b .
- the second partial cut 13 c includes two triangular shaped ears 16 a and a center portion 16 b , positioned such that a vertex of each triangle shape is towards the center of blank 2 .
- the tear strip ears 16 a and center portion 16 b form a male tab 16 that facilitates carton 1 being re-closed.
- Both the first and second partial cuts 13 b and 13 c expand outwardly with a taper near the side of carton 1 .
- the width of tear strip 13 facilitates enabling a person to grip the tear strip 13 .
- the second major flap 9 b also includes additional cuts 14 a and 14 b that extend substantially perpendicular to tear strip 13 .
- the third partial cut 14 a or outside cut, is near the miter corner and extends, across the width of second major flap 9 b .
- Cut 14 a extends through the depth of blank 2 , but does not penetrate the reverse face of blank 2 .
- Parallel and inward of outside cut 14 a , the fourth partial cut 14 b , or inside cut extends from the fold to the second partial cut 13 c .
- the inside cut 14 b penetrates the blank 2 , but not the reverse face of blank 2 .
- second section 2 b includes the second major lower flap 8 b .
- the second major lower flap 8 b is generally trapezoidally-shaped and includes a short base and a substantially parallel long base that is spaced apart from, and joined to the short base by a pair of edges.
- the short base is formed contiguously with a fold 12 c extending across the longitudinal side of front panel 3 .
- the long base is spaced from the center of the blank 2 towards the center of the assembled carton 1 .
- the pair of edges are substantially straight and have an end proximate to the short base that is truncated at an approximate forty-five degree angle.
- the miter flaps 6 b abut the second major lower flap 8 b at the truncated edges.
- the second major lower flap 8 b has a crease 12 d that extends across flap 8 a and is adjacent to the long base.
- the crease 12 d extends substantially parallel to the long base and overlaps the long base of first major lower flap 8 a .
- the crease 12 d permits the second major lower flap 8 b to fold over first major lower flap 8 a to form the sealed bottom 8 of carton 1 .
- third section 2 c is formed substantially similar to the first section 2 a .
- the third section 2 c extends outward from a side panel 5 , and more specifically, extends outward from the center of blank 2 along the longitudinal axis of blank 2 .
- This side panel 5 has a generally rectangular shape and is oriented such that the longitudinal axis of the side panel 5 is substantially perpendicular to the longitudinal axis of blank 2 . Similar to first section 2 a , the length of this side panel 5 establishes the general height of the finished carton 1 .
- the side panel 5 includes longitudinal creases 5 a and lateral folds 12 a that have a shorter length than the longitudinal creases 5 a .
- minor flaps 10 Extending away from the lateral folds 12 a at both ends, minor flaps 10 have a generally trapezoidal shape defined by a short base and a substantially parallel long base that is spaced apart from, and is joined to the short based by a pair of edges.
- the short base is formed contiguously with the side panel 5 along a fold line 12 a at a lateral end of side panel 5 .
- the minor flap 10 contacts a major and major lower flap.
- Miter panel 6 flank the side panel 5 , and couple the longitudinal creases 5 a of side panel 5 together.
- the longitudinal axes of the miter panels 6 are substantially parallel to the longitudinal axis of side panel 5 .
- the miter panels 6 are generally rectangular shaped and have a width that is less than, or equal to, approximately half the width of a side panel 5 .
- the miter panels 6 also include lateral folds 12 b and longitudinal creases 5 a .
- the lateral folds 12 b connect the miter flaps 6 b with the miter panels 6 .
- the miter flaps 6 b are generally triangular shaped and are oriented such that a base of the triangle is on the fold and the vertex of the triangle is spaced a distance away from the miter panel 6 .
- Each end of a miter panel 6 includes a miter flap 6 b .
- the miter flaps 6 b are cut separately from the minor flaps 10 , each miter flap 6 b contacts the major flap and major lower flaps.
- Fourth section 2 d is formed contiguous with the third section 2 c , or side panel 5 , and includes the rear panel 4 , appended first major flap 9 a , first major lower flap 8 a , and miter tab 7 .
- Rear panel 4 has a generally rectangular shape with a longitudinal axis that is substantially parallel to the longitudinal axis of blank 2 .
- the rear panel 4 includes lateral ends that are contiguous with creases 6 a 7 b to a miter panel 6 and to miter tab 7 , and longitudinal sides that are contiguous with folds 12 c to major flap 9 a and to major lower flap 8 a.
- First major flap 9 a is generally trapezoidal shaped with a short base and a substantially parallel long base that is spaced apart from, and joined to, the short base by a pair of edges.
- the short base is formed contiguously with a fold 12 c defined on the longitudinal side of rear panel 4
- the long base is positioned away from the center of the blank 2 , towards the center of the assembled carton 1 .
- the edges are substantially straight and with an end proximate to the short base that is truncated at an approximate 45° angle.
- a miter flap 6 b abuts the second major flap 9 b at the truncated edge closer to the center of blank 2 .
- First major flap 9 a is formed with a rectangular notch 17 along the long base.
- first and second major flaps 9 a and 9 b have approximately the same width.
- Major flap 9 a is formed with a plurality of cuts 15 a and 15 b that each extend substantially perpendicular to fold 12 c .
- the first cuts 15 a or outside cuts, are near the miter corners and extend across the width of the first major flap 9 a . Cuts 15 a extend through the depth of blank 2 , but do not penetrate the reverse face of blank 2 .
- the inside cuts 15 b penetrate blank 2 but not the reverse face of blank 2 .
- the first major lower flap 8 a is generally trapezoidal shaped and includes a short base and substantially parallel long base that is spaced apart from, and joined to, the short base by a pair of edges.
- the short base is formed contiguously with a fold extruding across the longitudinal side of front panel 3 .
- the long base is spaced from the center of blank 2 towards the center of the assembled carton 1 .
- the pair of edges are substantially straight and have an end proximate to the short base that is truncated at an approximate 45° angle.
- a miter flap 6 b abuts the first major lower flap 8 a at a truncated edge.
- the fourth section 2 d is opposite the miter panel 6 of third section 2 c , and includes a miter tab 7 that extends from the opposite end of rear panel 4 .
- Miter tab 7 has approximately the same width as miter panel 6 and is formed with a slight trapezoidal shape.
- the long base miter tab 7 forms a crease 7 b to rear panel 4 and the short base is substantially parallel to the long base and is free for attachment to first section 2 a during assembly of carton 1 .
- the miter tab 7 lacks miter flaps 6 b .
- the edges of miter tab 7 taper slightly away from the center of blank 2 such that notches 7 a are formed.
- the reverse face of blank 2 has adhesive 18 applied to seal the bottom 8 and later the top 9 of carton 1 . More specifically, in the exemplary embodiment, the reverse face has adhesive 18 applied in a generally triangular pattern to each minor flap 10 at each end of the short base. The vertex of the triangular adhesive pattern points towards the intersection of the fold 12 b and the crease 5 a for the miter panel 6 , while the base of each triangular adhesive pattern extends towards, and is substantially parallel to, the long base of the miter panel 6 .
- blank 2 includes eight generally triangular adhesive patterns.
- miter tab 7 has adhesive 18 applied across substantially its full length.
- Adhesive 18 facilitates securing miter tab 7 to miter panel 6 during assembly of carton 1 .
- Adhesive 18 is also applied outwards from miter panel 6 , to first major flap 9 a and first major lower flap 8 a along both edges of flaps 8 a and 9 a . More specifically, such adhesive 18 is applied to extend from the long base towards the short base along each flap 8 a and 9 a . During assembly, such adhesive 18 facilitates securing each flap 8 a and 9 a to lower minor flaps 10 after carton 1 is filled.
- Adhesive is also applied to second major flap 9 b and second major lower flap 8 b .
- adhesive 18 is applied along the long base of both flaps 8 b and 9 b and the edges of both flaps 8 b and 9 b , in a manner that is similar to adhesive applied to first major flap 9 a and first lower major flap 8 a.
- carton 1 Upon folding blank 2 with specialized machinery, described in more detail below, carton 1 is filled with a product, and second major flap 9 b is closed upon first major flap 9 a .
- Carton 1 when fully assembled, has a front established by the generally rectangular shaped front panel 3 and two flanking miter panels 6 .
- the miter panels 6 extend rearward from front panel 3 at an approximate forty-five degree angle.
- Side panels 5 extend further rearward from each miter panel 6 .
- the side panels 5 are generally perpendicular to front panel 3 and have a rectangular shape of lesser width than front panel 3 .
- Two additional miter panels 6 extend rearward from each side panel 5 at an approximate forty-five degree angle towards the rear panel 4 .
- the rear panel 4 is oriented substantially parallel to, and spaced apart from, front panel 3 .
- carton 1 has a generally octagonal shape and is generally symmetric about three axes when assembled and closed.
- Carton 1 has a top 9 that is closed after carton 1 is filled with product.
- Top 9 is substantially perpendicular to front panel 9 and is formed as the second major flap 9 b is folded inward upon the first major flap 9 a which is also folded inward.
- each flap 9 a and 9 b is sized to extend fully across top 9 when folded to close top 9 .
- the tear strip 13 of second major flap 9 b is positioned across top 9 to enable a consumer to use in opening carton 1 .
- the width of front panel 3 establishes the length of the finished carton 1 .
- the front panel 3 has a generally rectangular shape with two ends that are substantially perpendicular to the longitudinal axis of front panel 3 .
- a miter panel 6 extends rearward from each end of panel 3 at a crease 6 a .
- carton 1 has gaps 7 c that may be defined adjacent the top 9 and the bottom 8 of carton 1 . More specifically, in the front, the gaps 7 c are created when the second major flap 9 b is folded over the first major flap 9 a , and when the second major lower flap 8 b is folded over the first major lower flap 8 a .
- miter flaps 6 b extending from the miter panels 6 , substantially seal the gaps 7 c beneath the second major flap 9 b and the second major lower flap 8 b.
- the rear of carton 1 is opposite the carton front, as shown in FIG. 4 , and is defined by a rear panel 4 .
- rear panel 4 has a generally rectangular shape and is oriented such that two ends are substantially perpendicular to the longitudinal axis of front panel 3 .
- a miter panel 6 extends rearward from each rear panel end at a crease 6 a .
- rear panel 4 includes an edge 7 c wherein miter tab 7 is secured to a miter panel 6 .
- the second major flap 9 b Towards the top 9 of carton 1 , the second major flap 9 b includes an edge 9 c extending along the length of carton 1 , and towards the bottom 8 of carton 1 , the second major lower flap 8 b includes an edge extending along the length of carton 1 . At each end, gaps are defined at the carton top 9 and bottom 8 . Moreover, towards the rear of carton 1 , the gaps 7 c are created when the first major flap 9 a is folded beneath the second major flap 9 b , and the first major lower flap 8 a is folded under the second major lower flap 8 b . Miter flaps 6 b , extending from miter panels 6 , facilitate sealing the gaps 7 c above the first major flap 9 a and the first major lower flap 8 a to facilitate anti-sifting.
- a side of carton 1 is generally rectangular in shape as defined by side panel 5 .
- side panel 5 defines the height and depth of carton 1 .
- Each side includes two longitudinal edges.
- Miter panels 6 extend approximately forty-five degrees away from each longitudinal side panel edge towards the center of carton 1 . In the exemplary embodiment, the miter panels 6 are narrower than side panel 5 .
- the edges of the second major flap 9 b are folded and glued upon the first major flap 9 a .
- the second major lower flap 8 b is folded over and glued upon the first major lower flap 8 a.
- a top 9 of carton 1 when sealed, facilitates containing product during shipment and handling, and enables a consumer to release product from carton 1 via tear strip 13 .
- the carton 1 has a generally octagonal shape.
- Front panel 3 and rear panel 4 are the widest panels, and miter panels 6 are the narrowest panels.
- Tear strip 13 extends substantially parallel to, and spaced apart from, the edge 9 c of second major flap 9 b .
- Tear strip 13 includes a thin line of tape 11 upon the reverse face of second major flap 9 b , and is formed with a plurality of partial cuts. Specifically, the first partial cut 13 b is towards the edge, and extends for the length of second major flap 9 b .
- the second partial cut 13 c is spaced apart from, and substantially parallel to, the first partial cut 13 b .
- the second partial cut 13 c extends across two portions of the second major flap 9 b and includes has two triangular shaped ears 16 a and a center portion that are oriented such that the vertex of the triangle shape extends towards the center of the blank 2 . Upon removal of tear strip 13 , the ears 16 a and the center portion form a male tab 16 that enables carton 1 to be re-closed.
- the carton top 9 is also formed with additional cuts that facilitate positioning the second and first major flaps 9 a and 9 b away from the mitered and sealed corners.
- the second major flap 9 b includes cuts that extend substantially perpendicular to tear strip 13 .
- the third partial cuts or outside cuts 14 a are positioned closer to the miter panels 6 and extend substantially across the width of the second major flap 9 b
- the fourth partial cuts or inside cuts 14 b extend from the fold to the second partial cut 13 c .
- the fourth partial cuts 14 b are substantially parallel to, and inward of, the outside cuts 14 a .
- the outside cuts 14 a and the inside cuts 14 b extend through the depth of blank 2 , but do not penetrate the reverse face of blank 2 .
- the first major flap 9 a includes cuts that are formed substantially collinear with cuts 14 a and 14 b upon the second major flap 9 b .
- the first partial cuts or outside cuts 15 a are near the miter panels 6 and extend substantially across the width of the first major flap 9 a .
- the second partial cuts or inside cuts 15 b extend from the fold towards the long base.
- the outside cuts 15 a and the inside cuts 15 b extend through the depth of the blank 2 , but do not penetrate the reverse face of blank 2 .
- the cuts 14 a , 14 b , 15 a , and 15 b , formed in top 9 define a rectangular portion of the top 9 for separation from the sealed corners.
- carton 1 has a bottom 8 that is generally octagonal shaped that is defined as the second major lower flap 8 b is folded over the first major lower flap 8 a .
- the second major lower flap 8 a includes a crease 12 d that extends substantially parallel to the longitudinal axis of carton 1 and that overlaps the long edge of the first major lower flap 8 a .
- the crease 12 d enables the second major lower flap 8 b to bend over the first major lower flap 8 a to substantially seal the bottom 8 of carton 1 .
- a consumer During use, to release product from carton 1 , a consumer initially removes tear strip 13 . As described above, the tear strip 13 has partial knife cuts 13 b and 13 c that are backed by tape 11 extending along the length of the second major flap 9 b . After pulling and removing tear strip 13 , further opening occurs along partial and full die cuts 14 a , 14 b , 15 a , and 15 b , as well as along perforations that enable a consumer to pull away the remaining second major flap 9 b .
- the hinged connection of the second major flap 9 b to the carton 1 facilitates a consumer easily separating the second major flap 9 b from the remainder of top 9 .
- the first major flap 9 a is opened by the consumer in a similar manner.
- Both major flaps 9 a and 9 b rotate about a fold line 12 c after delaminating from full die cuts 14 a and 14 b .
- the full die cuts extending through the press applied tape 11 , cleanly expose the remainder of the major flaps 9 a and 9 b and the male re-close feature 16 .
- the partial die cuts 14 a and 14 b are formed with a sufficient depth to cut the press applied tape 11 such that top 9 may be opened along the inside and the outside partial cuts 14 a and 14 b .
- the paperboard then delaminates and reveals the granulated product within the carton 1 .
- a consumer To close the carton 1 , a consumer initially rotates the first major flap 9 a towards the carton top 9 .
- the first major flap 9 a is formed with a female notch 17 while the second major flap 9 b is formed with a male tab 16 .
- the male tab 16 may be inserted into the female notch 17 .
- the male tab 16 and female notch 17 are interlocked and carton 1 is re-closed.
- a specialized machine is used to form carton 1 from a blank of sheet material, such as blank 2 .
- the machine will be discussed hereafter with reference to forming carton 1 from blank 2 .
- the machine may be used to form a carton having any size, shape, or configuration from a blank having any size, shape, or configuration without departing from the scope of the present invention.
- the machine includes a loading section for loading blanks 2 into the machine for formation into cartons 1 .
- each blank 2 is loaded into a loading frame that supports the blank 2 in a generally vertical position.
- a conveyor moves the blank 2 into a transfer section as the loading frame supports the blank 2 .
- a gripping member lifts the blank 2 out of the loading frame and places it onto a support in a generally horizontal position.
- the gripping member includes a plurality of vacuum cups connected to a rotating frame. The vacuum cups attach to the blank 2 and grip the blank 2 as the rotating frame positions the blank 2 over the support in front of a pusher assembly. The vacuum cups then release their grip to place the blank 2 onto the support.
- the pusher assembly pushes the blank over three hot melt glue guns wherein adhesive is applied to surfaces of carton 1 as described above.
- the pusher assembly guides the blank 2 along the support until the blank is underneath a mandrel mounted on the machine.
- the mandrel has an external shape that is complimentary to at least a portion of an internal shape of the carton 1 formed from the blank.
- the pusher assembly pushes the blank 2 along the support such that the rear panel is positioned underneath the mandrel and the fold lines are aligned with respective outer edges of the mandrel.
- Any suitably configured member may be used to facilitate folding carton 1 as described herein.
- a flap folder member may be used to fold the carton flaps to assembly carton 1 .
- an anti-sifting carton assembled has a polygonal shape, such as an octagon.
- the carton is capable of storing granulated product such that sifting of the product from the carton is facilitated to be minimized.
- the above-described carton also facilitates reducing sealing and forming problems that may be associated with known cartons.
- the present invention provides a single piece bulk granular product carton that is formed from a single blank having major flaps, lower major flaps, minor flaps, miter flaps, emboss pads, a front panel, a real panel, miter panels, notches, and a tear strip.
- the panels form the octagonal-shaped carton with the flaps used for sealing the ends of the carton. Specially, the flaps overlap to seal the four corners of each end. As a result, the sealed ends, facilitated reducing sifting and/or other losses of granulated product from the carton in a cost-effective and reliable manner.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
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Abstract
Description
Claims (12)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US11/548,959 US7690554B2 (en) | 2005-02-14 | 2006-10-12 | Anti-sifting polygonal carton and methods of assembly |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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US65259805P | 2005-02-14 | 2005-02-14 | |
US11/347,915 US7731080B2 (en) | 2005-02-14 | 2006-02-06 | Anti-sifting polygonal carton |
US11/548,959 US7690554B2 (en) | 2005-02-14 | 2006-10-12 | Anti-sifting polygonal carton and methods of assembly |
Related Parent Applications (1)
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US11/347,915 Continuation-In-Part US7731080B2 (en) | 2005-02-14 | 2006-02-06 | Anti-sifting polygonal carton |
Publications (2)
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US20070063002A1 US20070063002A1 (en) | 2007-03-22 |
US7690554B2 true US7690554B2 (en) | 2010-04-06 |
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US20110180594A1 (en) * | 2010-01-25 | 2011-07-28 | Fitzwater Kelly R | Package for Multiple Food Items |
USD668144S1 (en) * | 2011-07-08 | 2012-10-02 | Kohler Co. | Packaging for plumbing fixtures |
US8763803B2 (en) | 2011-07-07 | 2014-07-01 | Kohler Co. | Packaging for plumbing fixtures |
USD737135S1 (en) * | 2014-07-17 | 2015-08-25 | Seiko Epson Corporation | Ink cartridge box for printers |
US9708111B1 (en) * | 2016-12-19 | 2017-07-18 | Jennifer Prince | Packaging sheet for box or wrapping |
WO2018118583A1 (en) * | 2016-12-19 | 2018-06-28 | Jennifer Prince | Packaging sheet for box or wrapping |
US10239651B2 (en) | 2017-01-13 | 2019-03-26 | Graphic Packaging International, Llc | Carton with top closure |
US10246234B2 (en) * | 2016-12-19 | 2019-04-02 | Five Little Princes Development, Llc | Packaging sheet for box or wrapping |
USD859983S1 (en) | 2016-12-19 | 2019-09-17 | Five Little Princes Development, Llc | Packaging sheet for box or wrapping |
USD896638S1 (en) | 2016-12-19 | 2020-09-22 | Five Little Princes Development, Llc | Packaging sheet for box or wrapping |
US20200407103A1 (en) * | 2019-06-27 | 2020-12-31 | Westrock Shared Services, Llc | Shippers with a constant depth |
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US7731080B2 (en) * | 2005-02-14 | 2010-06-08 | Graphic Packaging International, Inc. | Anti-sifting polygonal carton |
US20090039144A1 (en) * | 2007-08-08 | 2009-02-12 | Hooi Koon H | Folded food carton |
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Cited By (15)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20110180594A1 (en) * | 2010-01-25 | 2011-07-28 | Fitzwater Kelly R | Package for Multiple Food Items |
US8763803B2 (en) | 2011-07-07 | 2014-07-01 | Kohler Co. | Packaging for plumbing fixtures |
US9233774B2 (en) | 2011-07-07 | 2016-01-12 | Kohler Co. | Packaging for plumbing fixtures |
USD668144S1 (en) * | 2011-07-08 | 2012-10-02 | Kohler Co. | Packaging for plumbing fixtures |
USD737135S1 (en) * | 2014-07-17 | 2015-08-25 | Seiko Epson Corporation | Ink cartridge box for printers |
WO2018118583A1 (en) * | 2016-12-19 | 2018-06-28 | Jennifer Prince | Packaging sheet for box or wrapping |
US9708111B1 (en) * | 2016-12-19 | 2017-07-18 | Jennifer Prince | Packaging sheet for box or wrapping |
US10246234B2 (en) * | 2016-12-19 | 2019-04-02 | Five Little Princes Development, Llc | Packaging sheet for box or wrapping |
USD859983S1 (en) | 2016-12-19 | 2019-09-17 | Five Little Princes Development, Llc | Packaging sheet for box or wrapping |
USD859982S1 (en) | 2016-12-19 | 2019-09-17 | Five Little Princes Development, Llc | Packaging sheet for box or wrapping |
USD896638S1 (en) | 2016-12-19 | 2020-09-22 | Five Little Princes Development, Llc | Packaging sheet for box or wrapping |
US10239651B2 (en) | 2017-01-13 | 2019-03-26 | Graphic Packaging International, Llc | Carton with top closure |
US20200407103A1 (en) * | 2019-06-27 | 2020-12-31 | Westrock Shared Services, Llc | Shippers with a constant depth |
US11066208B2 (en) * | 2019-06-27 | 2021-07-20 | Westrock Shared Services, Llc | Shippers with a constant depth |
US11511907B2 (en) | 2019-06-27 | 2022-11-29 | Westrock Shared Services, Llc | Shippers with a constant depth |
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